Folder for business forms

ABSTRACT

A machine for producing zigzag folds in continuous business forms or like strip material. The strip material moves over a horizontal feed roller and then downward between a pair of opposed endless belt units to an underlying support surface. A hold-down roller is biased to engage the feed roller, with the material sandwiched therebetween, immediately above the point at which the material discharges from the feed roller. The material, upon engagement with the support surface, loops alternately in opposite directions beneath the belt units and between spaced stops, one of which is rounded so as to allow for a smooth continuous movement of the folded material therebeyond. Material boosting means periodically engage the looped material immediately prior to engagement with the stops so as to insure a proper movement thereagainst.

United States Patent 1 Bunch, Jr.

[451 Jan. 16, 1973 [54] FOLDER FOR BUSINESS FORMS [76] Inventor: EarnestR. Bunch, Jr., 3050 West Corrine Drive, Phoenix, Aria 85029 22 Filed:Aug. 28, 1970 21 Appl. No.: 67,927

Primary Examiner-Lawrence Charles Att0rney-Clarence A..OBrien and HarveyB. Jacobson . [57] ABSTRACT A machine for producing zigzag folds incontinuous business forms or like strip material. The strip materialmoves over a horizontal feed roller and then downward between a pair ofopposed endless belt units to an underlying support surface. A hold-downroller is biased to engage the feed roller, with the material sandwichedtherebetween, immediately above the point at which the materialdischarges from the feed roller. The material, upon engagement with thesupport surface, loops alternately in opposite directions beneath thebelt units and between spaced stops, one of which is rounded so as toallow for a smooth continuous movement of the folded materialtherebeyond. Material boosting means periodically engage the loopedmaterial immediately prior to engagement with the stops so as to insurea proper movement thereagainst.

11 Claims, 6 Drawing Figures so /02 I W LVMJ PATENTEDJKN 16 I975 SHEET 1OF 3 Earnest B. Bunch, Jr.

1N IEXTOR.

BY WWW PATENTED AHBI Y 3.711.085

SHEET 2 OF 3 9Q Earn es/ 5. Bunch, Jr.

INVESTOR.

PATENTEDJAN 16 I973 SHEET 3 [IF 3 Ear/res! B, Bunch, Jr.

IXVL NTOR.

lliiii 7 WW EMMA? FOLDER FOR BUSINESS FORMS The invention hereingenerally relates to machines 7 for forming alternate or zigzag folds incontinuous 7 material, such as business forms or the like. More parfromthe machine in a smooth continuous flow so as to facilitate thesubsequent packaging thereof.

In known machines of a generally similar design,

the machine. The roll spindle in turn wil normally be' mounted onbrackets affixed to and projecting from'the various problems have arisenincluding the tendency for the introduced strip material to wrap aroundor become entangled with the feed roller and a tendency for the foldedmaterial to exit from the machine in bunches, rather than a smoothcontinuous flow. Difficulties have also been encountered in adjustingthe stops so as to accommodate materials of different thicknesses orfolds of varying depths.

It is to overcome the above deficiencies that the present invention hasbeen devised. More particularly, the machine herein incorporates a feedroller and holddown roller arrangement whereby a positive feeding of thestrip material into the folding portion of the machine can be effectedwithout any danger of the material wrapping about the feed roller orbeing improperly fed. In addition,the material handling and foldingelements have been so constructed and orientated as to provide for acontinuous folding operation wherein there is effected both a smoothpositive folding of the strip and a discharge of the finished productwithout breaks or bunches. Such advantages are achieved through theutilization of special roller guided flat belts on the material movingbelt units, stops, and particularly a stop at the discharge end of themachine, which cooperate in producing the folds and providing for asmooth discharge of the folded material, material boosting meansassociated with each stop with such means consisting of spaced rotatingrelatively narrow fingers which only periodically engage the materialand do not disrupt'the smooth flow thereof. Both the stops and materialboosting means associated therewith are mounted for positive adjustmentthrough a pinion and rack arrangement.

These together with other objects and advantages which will becomesubsequently apparent reside in the details of construction andoperation as more fully hereinafter described and claimed, referencebeing had to the accompanying drawings forming a part hereof, whereinlike numerals refer to like parts throughout, and in which:

FIG. 1 is a perspective view of the material feeding, folding anddischarge portion of the machine, the supply roll not being illustrated;

FIG. 2 is a top plan view of the machine as shown in FIG. I;

. FIG. 3 is an enlarged longitudinal cross-sectional view through themachine;

FIG. 4 is an enlarged cross-sectional detail taken substantially on aplane passing along line 4-4 in FIG. 3;

FIG. 5 is a perspective detail of the stop and material boosting meansat the discharge or outlet end of the machine; and

FIG. 6 is a cross-sectional detail similar to the central portion ofFIG. 3 illustrating the material boosting means in a rotated position.

Referring now more specifically to the drawings, the machine includes arigid frame 10 having a front or near side 12 from which the machine isoperated, a rear or far side 14 on which the drive train will bemounted,

an input end 16, and an output or discharge end 18.

The strip material or paper to be folded will normally be'provided in anenlarged roll mounted on a spindle outward of and in alignment with theinput end 16 of frame 10. It is contemplated that an adjustable brake beutilized so as to provide for an even drag on the stock material. Thepaper itself will be preperforated at regular intervals with it beingthe function of the machine to form the folds along the perforations.

An elongated feed roller 20 extends transversely across the machineframe 10 and is mounted on a the frame 10. This roller 20 is locatedgenerally centrally of the frame 10 and receives the introduced strip ofmaterial or paper 24 thereover for discharge downwardly between a pairof belt units 26 and 28. The strip of material 24 is frictionally heldagainst the feed roller 20 by a cooperating hold-down roller 30. Thehold-down roller 30 has the shaft thereof rotatably journaled on thefree ends of a pair of swinging arms 32 pivotally supported by anelongated shaft 34 extending between and supported by the opposed frontand rear frame side walls.-The hold-down roller 30 is so orientated asto engagethe forward face of the feed roller 20 at or just above thepoint at which the strip of material 24 moves downward away from theroller 20. This specific positioning of the hold-down roller 30 isconsidered particularly significant in that heretofore the hold-downroller has been positioned so as to engage the feed roller 20 along thetop thereof and substantially spaced from the point of discharge of thepaper. Thus, there existed a substantial tendency for the material toimproperly feed, and in fact sometimes wrap around the feed rolleritself, thus causing a complete shutdown of the machine until a clearingof the blockage was effected. In order to vary the frictional grip onthe material, a weight 36 is slidably mounted on an outwardly projectingrod 38 engaged with a crossbar 40 fixed between the swinging arms 32.Appropriate setscrew means 42 is utilized to lock the weight 36 in thedesired adjusted position.

Each of the belt units 26 and 28 is orientated longitudinally along theframe 10 between the input and output ends 16 and l8'thereof, andincludes side plates or panels 44. Each pair of side plates 44 pivotallymounts on an inner drive roller 46, the shaft of which is journalled inthe front and rear sides of the frame 10. The plates 44 in turn mount anouter adjustable idler roller 48, spaced endless belts 50 engaging aboutthe rollers 46 and 48. These belts are flat rather than V-belts andthereby enable the utilization of smooth rollers and also allow for aprecision weaving of the belt so as to specifically adapt them for paperhandling. A belt guide 52 is also mounted on each belt unit 26 and 28below the upper run of the spacedflat belts 50 and immediately outwardof the corresponding drive roller 46. Each of the guides 52 consists ofan elongated shaft 54 having the opposed ends thereofjournaled in theopposed side plates 44, and a series of spaced roller sections 56 whichreceive the belts 50 therebetween so as to maintain the belt spacing.

A pair of mounting blocks 58 are positioned immediately inwardof theside panels 44 of each of the belt units 26 and 28, each of these blocks58 being slidably mounted on an elongated guide rod 60 fixed to thecorresponding side panel 44 in inwardly spaced relation thereto. Anappropriate setscrew or the like 62 is threaded downwardly through theupper portion of each of the mounting blocks 58 for selective engagementwith the guide rod 60 for a locking of the block 58 thereto in anyadjusted position. The adjustment of each pair of blocks 58 issynchronized, utilizing an elongated shaft 64 extending transverselyacross the corresponding unit and through the upper portions of theassociated blocks 58. The shaft 64, immediately beyond each 'oftheblocks 58, mounts a pinion 66 thereon which inturn engages with anelongated rack 68 defined along the upper edge of the adjacent sidepanel 44. The rod or shaft 64, at the front of the machine, projectsforwardly and mounts a manually manipulable handle 70 which, upon beingrotated, effects a synchronized positive longitudinal adjustment of themounting blocks 58 without any slippage or necessity for readjustmentsuch as would occur were stretchable chains and sprockets utilized. Oncethe blocks 58 are positioned where desired, the locking setscrews 62 areengaged with the guide rods 60.

Each pair of blocks 58 mounts abutment means or a stop assembly whichextends transversely therebetween. The stop assembly associated with thebelt unit 28 toward the input end 16 of the machine is designated byreference numeral 72, while the'stop assembly associated with the beltunit 26 toward the output end 18 of the machine is designated byreference numeral 74. Each stop assembly 72 and 74 includes an elongatedflat base plate or flange 76 transversely underlying the lower runs ofthe belts 50 of the associated belt unit and having the opposite endsthereof rigidly affixed to the lower ends of the associated blocks 58.The stop assembly 72 is completed by a series of upwardly directedfingers 78 projecting perpendicularly from the inner edge of theassociated base flange 76 at right angles thereto, these fingers 78projecting upwardly between the associated belts 50 and being spaced soas to accommodate the belts 50 therebetween.

With regard to the abutment means or stop assembly 74 associated withthe belt unit 26, fingers 80 are likewise provided on the inner edge ofthe associated base plate or flange 76. However, these fingers 80,rather than defining a sharp right angular corner with the inner edge ofthe plate 76, have smooth arcuately curved lower end portions whichengage the inner edge of the flange 76 and provide a rounded cornerabout which 1 the folded stock can flow both evenly and smoothly. The,upper portion of each of the fingers 80 is orientated perpendicular tothe associated base flange 76 as has been done heretofore. However, itis the curving of the lower portions of the fingers 80 which isconsidered particularly unique and highly significant as a means forensuring an effective flow of the folded stock from the machine.Incidentally, it will of course be appreciated that the fingers are alsospaced for the ac commodation of the associated belts 50.

Positioned immediately inward of each stop assembly, and in parallelspaced relation thereto, is a material positioning or boosting means 82.Each of these means 82 consist of an elongated shaft 84 overlying thelower runs of the associated belts 50 and having the opposite endsthereof journaled in the opposed mounting blocks 58. The shaft 84 is sopositioned as to be in contact with the upper surfaces of the lower runsof the belts 50 for a rotational driving of the shaft 84. The actualboosting engagement with the folded paper is effected by means of aseries of radially projecting short rod sections or fingers 86 fixed tothe shaft 84 in diametrically I opposed pairs at spaced pointstherealong. Each of these thin projecting sections terminates in aflattened outer end which provides for point contact with the paper foldimmediately therebeneath just prior to an engagement of the fold againstthe corresponding stop assembly. Each material boosting means ispositioned at a critical point where the folded stock has a tendency toslow down prior to reaching the associated stop assembly. The fingers 86engage the stock momentarily so as to ensure proper movement of thestock against the stop, the fingers 86 loosing contact with the stockprior to an engagement of the stock with the stop. This is contrary tothe folding and boosting means provided on similar machines such as thatillustrated in the Preston patent. For example, the boosting orimpressing rollers in Preston remain in contact with the several lastfolded sheets, thus tending to provide a continuing varying pressure onthe sheets and producing high and low places whereby the next sheet tobe fed thereon can, because of the continuous engagement, be eitherstopped completely or misfolded. Such problems are avoided in the devicedetailed herein.

Positioned beneath the belt unit 26, at the output end of the machine,is a table or table-like horizontal panel 88. A series of flat conveyorbelts have the upper runs thereof extending over the panel 88 andrearwardly therebeyond about a transverse drive roller 92. The belts 90also extend about an idler roller (not illustrated), at the output endof the panel 88 whereby a continuous traveling of the belts 90 can beeffected for a discharge of the folded material or stock at the outputend of the machine. The tabletop or panel 88 can, as will be appreciatedfrom FIG. 3, terminate short of the paperaccommodating space between theupper belt sections 26 and 28, with the overlying belts 90 forming asupport surface on which the material 24 folds. Alternately, the panel88 can be extended rearwardly so as to combine with the belts inproviding a paper accommodating support surface.

A vertical adjustment of the' delivery table belts 90, rearward of thetable panel 88, is provided for by means ofa transversely elongatedroller 94 mounted on an extending between the free ends ofa pair of arms96 pivoted to the opposed portions of the machine frame 10, an upwardlydirected adjusting screw 98 engaging upwardly against one of the arms 96so as to provide the desired upward or downward swung positioning of theroller 94. As will be best appreciated from FIG. 3, this roller 94 islocated immediately forward of the back fold forming booster means andstop assembly so StatesPatent 1 1 Weist 4 u] 3,711,086 I i 51 Ji 16,1973

METHOD PPARATUS-1 0R 3 FOLDING LENGTHSOF MATERIAL 611 Avenue,Louisville,'Ky. 40206 Filed: 'Sept.1, 1910- Appl.No.: 68,631

93/1 93/8, 270/61, 270/69 Int. Cl. ..B65h 45/18 Field of Search..270/6l, 69, 83-85, 270/67, 76; 93/1, 8; 53/116, 117,120,118

References Cited I. i

- UNITED STATES PATENTS 3.590. 91 7 1971 Schaflron. "270/61 Inventor:Herman C. Weist 1860 Arlington I Primary ExaminerRobefl Michell-Assistant Examiner-L. R. Oremland Attorney- William R. Price Lengths ofmaterial, suchas plastic bags, fed from a more times prepatory topackaging. Each length of material is wrapped aroundspaced, and axiallyopposed vacuurn pickup rollers to form a hollow cylindrieal'roll on saidrollers. The roll is then bent in half by means of a blunt edge bladedisposed with its lon-,

18 Claims, 7 Drawing Figures "ABSTRACT.

1. For use in a machine for making continuous zigzag folds in a strip offlexible material by the feeding of the material toward a supportsurface for an alternate looping of the material in opposite directions,a pair of stop assemblies above the support surface and spaced apart tothe opposite sides of the point at which the material is fed, each stopassembly extending transversely of the material and having upstandingabutment means thereon for engagement of the material loops against oneface thereof, a first one of said stop assemblies being positionedfurther from the support surface than the second of said stopassemblies, the abutment means on the first stop assembly having a lowerend portion curving smoothly away from the face against which thematerial loops engage, said abutment means comprising a plurality oflaterally spaced upstanding fingers, each stop assembly including anelongated flange extending along and interconnecting the lower ends ofsaid fingers, said flange being orientated at approximately 90* to saidfingers, and a material boosting means parallel to each stop assembly inspaced relation forward of the loop engaging face of the abutment meansthereon, each material boosting means comprising an elongated rotatableshaft positioned above the lower portion of the corresponding stopassembly fingers, each shaft having material engaging narrow fingersfixed thereto and projecting outwardly therefrom at spaced pointstherealong, said shaft fingers, at each of the spaced points along theshaft, consisting of a single pair of fingers with the fingers of eachpair being diametrically opposed from each other.
 2. The construction ofclaim 1 wherein the boosting means fingers are of a length so as toterminate in spaced relation to the stop assembly fingers during therotation of the material boosting means and engage and subsequentlydisengage from the material prior to the material engaging the stopassembly.
 3. The construction of claim 2 including an endless drivenbelt unit positioned to each side of the fed strip of mateRial, eachbelt unit overlying one of said stop assemblies and the associatedmaterial boosting means, each stop assembly and the associated materialboosting means being mounted on laterally spaced mounting blocks, eachmounting block having a rotatable pinion thereon, the associated beltunit having a pair of elongated racks, and means for effecting aselective travel of the pinions along the racks for an adjustment of theposition of the corresponding stop assembly and associated materialboosting means.
 4. The construction of claim 3 including an elongatedguide rod fixed to each belt unit adjacent each mounting block for asliding guided movement of the block therealong, and lock means forselectively locking each block to the associated guide rod at anyadjusted position therealong.
 5. The construction of claim 4 whereinsaid belt units alternately engage and guide the said strip of material,said belt units consisting of inner and outer end rollers having aseries of laterally spaced flat material gripping belts engagedthereover for a frictional gripping of the strip of material.
 6. Theconstruction of claim 5 including a positioning roller associated witheach belt unit, said positioning roller underlying the spaced beltstransversely thereacross and including a plurality of spaced outwardlyprojecting roller sections receiving and guiding the flat beltstherebetween.
 7. The construction of claim 6 including an elongated feedroller positioned above the belt units for an initial movement of thestrip of material thereover, said feed roller being so positioned as toenable a downwardly movement of the strip of material between the beltunits, said strip of material discharging from the feed roller in agenerally vertical plane tangential to the roller, and a hold-downroller cooperating with the feed roller for a frictional gripping of thestrip of material therebetween, said hold-down roller engaging thematerial against the feed roller approximately at the point of dischargeof the strip of material from the feed roller.
 8. The construction ofclaim 1 including an endless driven belt unit positioned to each side ofthe feed strip of material, each belt unit overlying one of said stopassemblies and the associated material boosting means, each stopassembly and the associated material boosting means being mounted onlaterally spaced mounting blocks, each mounting block having a rotatablepinion thereon, the associated belt unit having a pair of elongatedracks, and means for effecting a selective travel of the pinions alongthe racks for an adjustment of the position of the corresponding stopassembly and associated material boosting means.
 9. The construction ofclaim 8 wherein said belt units alternately engage and guide the saidstrip of material, said belt units consisting of inner and outer endrollers having a series of laterally spaced flat material gripping beltsengaged thereover for a frictional gripping of the strip of material, apositioning roller associated with each belt unit, said positioningroller underlying the spaced belts transversely thereacross andincluding a plurality of spaced outwardly projecting roller sectionsreceiving and guiding the flat belts therebetween.
 10. The constructionof claim 8 including an elongated feed roller positioned above the beltunits for an initial movement of the strip of material thereover, saidfeed roller being so positioned as to enable a downward movement of thestrip of material between the belt units, said strip of materialdischarging from the feed roller in a generally vertical planetangential to the roller, and a hold-down roller cooperating with thefeed roller for a frictional gripping of the strip of materialtherebetween, said hold-down roller engaging the material against thefeed roller approximately at the point of discharge of the strip ofmaterial from the feed roller.
 11. For use in a machine for makingcontinuous zigzag folds in a strip of flexible material by the feEdingof the material toward a support surface for an alternate looping of thematerial in opposite directions, a pair of stop assemblies above thesupport surface and spaced apart to the opposite sides of the point atwhich the material is fed, each stop assembly extending transversely ofthe material and having upstanding abutment means thereon for engagementof the material loops against one face thereof, a first one of said stopassemblies being positioned further from the support surface than thesecond of said stop assemblies, a material boosting means parallel toeach stop assembly in spaced relation forward of the loop engaging faceof the abutment means thereon, each material boosting means comprisingan elongated rotatable shaft positioned above the lower portion of thecorresponding stop assembly fingers, each shaft having material engagingnarrow fingers fixed thereto and projecting outwardly therefrom atspaced points therealong, said shaft fingers, at each of the spacedpoints along the shaft, consisting of a single pair of fingers with thefingers of each pair being diametrically opposed from each other, theboosting means fingers are of a length so as to terminate in spacedrelation to the stop assembly fingers during the rotation of thematerial boosting means and engage and subsequently disengage from thematerial prior to the material engaging the stop assembly.